Upgrading paraffins to distillates and lubricant basestocks

Abstract

A process for converting light paraffins (especially C3-C5) to middle distillate and higher boiling range liquid hydrocarbons by (1) oxygen or air oxidation of iso-paraffins to alkyl hydroperoxides; (2) conversion of alkyl hydroperoxides to dialkyl peroxides; (3) radical coupling of paraffins using the dialkyl peroxides as radical initiators forming heavier hydrocarbon products; and (4) fractionation of the heavy hydrocarbon products. The net reaction is catalytically converting light paraffins to heavier hydrocarbons using oxygen or air to effect the conversion.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application claims priority to U.S. Provisional Application Ser. No. 62 / 092,485 filed Dec. 16, 2014, herein incorporated by reference in its entirety.FIELD OF THE INVENTION[0002]This invention relates to a process to upgrade paraffins to higher value products such as lubricant basestocks, jet and diesel fuels. The process is particularly applicable to the upgrading of light paraffins (C2-C12). Light paraffins of this kind are commonly found in Natural Gas Liquids (NGL), tight oils (light crude oil contained in petroleum-bearing formations of low permeability, often shale or tight sandstone, also referred to as light tight oils), as well as fractions from various refining and / or chemical streams.BACKGROUND OF THE INVENTION[0003]With the increasing production of shale gas and tight oils, the supply of light paraffins (e.g., C2-C8, especially C2-C5 paraffins) is increasing at an unprecedented rate in the North America region; a large fr...

AI Technical Summary

Benefits of technology

The process described in this patent allows for the conversion of paraffins to higher value products like gasoline, middle distillates, and lubricant basestocks. The process involves oxidizing paraffins with oxygen and controlling the reaction severity to form heavier hydrocarbon products such as lubricant basestocks. Byproducts like alcohol can be blended with gasoline or converted into chemical products. This technology is particularly useful for light paraffins in the C2-C12 range.

Problems solved by technology

Although diluent use of C5s for heavy crude is predicted to grow somewhat, the supply of C4s / C5s is quickly outpacing demand and the imbalance will become worse with time.

Upgrading C4 / C5 paraffins to higher value and large volume products, while desirable, remains challenging.

Conversion of C4 / C5 paraffins to heavier hydrocarbon products such as kerojet, diesel fuels as well as lubricant basestocks would provide a large volume and higher value outlet to help alleviate the excess of light ends in the North American market; but there is no current commercial process directly converting light paraffins to heavier hydrocarbons such as these.

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